Abrasive roll and method for manufacturing abrasive roller

ABSTRACT

Object: Provided are an abrasive roll capable of easily improving abrasiveness and a method for manufacturing an abrasive roll. Solution: An abrasive roll (1) includes a core member (12) extending in the axial direction and an abrasive part (13) including a sheet (14) member of non-woven fabric wound a plurality of times around the core member (13), wherein a plurality of perforations (16) penetrating in the thickness direction of the sheet member (14) are formed in the sheet member (14).

TECHNICAL FIELD

The present invention relates to an abrasive roll and a method for manufacturing an abrasive roll.

BACKGROUND ART

An abrasive roll configured by winding a sheet of non-woven fabric a plurality of times around a core member has been known in the related art. For example, the abrasive roll of Patent Document 1 is used to abrade an object by rotating it in a state where the object contacts the outer circumferential surface.

PRIOR ART DOCUMENTS Patent Documents

Patent Document 1: JP H9-201232 A

SUMMARY OF THE INVENTION Problem to be Solved by the Invention

Here, with an abrasive roll like that described above, an object can be efficiently abraded by improving abrasiveness. Furthermore, improvement of abrasiveness of such an abrasive roll needs to be achieved using a simple structure. Based on the above, there has been a demand for easily improving the abrasiveness of an abrasive roll.

Means for Solving the Problem

An abrasive roll according to one aspect of the present invention includes a core member extending in the axial direction and an abrasive part including a sheet member of non-woven fabric wound a plurality of times around the core member, wherein a plurality of perforations penetrating in the thickness direction of the sheet member are formed in the sheet member.

Effect of the Invention

According to the present invention, provided are an abrasive roll capable of easily improving abrasiveness and a method for manufacturing an abrasive roll.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an abrasive roll according to an embodiment.

FIG. 2 is a drawing illustrating an outer circumferential surface of an abrasive roll viewed from the radial direction.

FIG. 3 is a drawing illustrating a sheet member in an unwound state.

FIG. 4 is a schematic view illustrating an apparatus for winding a sheet member around a core member.

FIG. 5 is a drawing illustrating a roll body in which a sheet member has been wound around a core member.

FIG. 6 is a schematic view illustrating an apparatus for adhering an adhesive liquid on a sheet member.

FIG. 7 is a figure illustrating an outer circumferential surface of an abrasive roll according to a modified example viewed from the radial direction.

FIG. 8 is a figure illustrating an outer circumferential surface of an abrasive roll according to a modified example viewed from the radial direction.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Detailed descriptions of embodiments according to the present invention are given below with reference to the attached drawings. Note that, in the following descriptions, the same reference symbols have been assigned to elements that are the same or equivalent, and that redundant descriptions thereof have been omitted.

An abrasive roll 1 according to an embodiment of the present invention will be described with reference to FIGS. 1 and 2. FIG. 1 is a side view of an abrasive roll. FIG. 2 is a partially enlarged view illustrating the abrasive roll 1 viewed from the circumferential direction. As illustrated in FIG. 1, the abrasive roll 1 includes a core member 12 and an abrasive part 13. Note that in the present embodiment, the center of the abrasive roll 1 is considered to be the center axis line CL, and the direction in which the center axis line CL extends is sometimes called the “axial direction.”

The core member 12 is a cylindrical member which extends along the axial direction. The core member 12 functions as a core when a non-woven fabric sheet member 14 to be described later is wound around it. The core member 12 is formed from a ferrous or non-ferrous material or the like.

The abrasive part 13 includes a non-woven fabric sheet member 14 wound around the core member 12 (refer to FIG. 3). The sheet member 14 is wound around the core member 12 a plurality of times in a spiral form. As a result, the abrasive part 13 has a structure in which a plurality of layers of the sheet member 14 are layered in the radial direction. The abrasive part 13 is a toric member formed on the outer circumferential side of the core member 12. The abrasive part 13 has a pair of end faces 13 a and 13 b which oppose each other in the axial direction, and an outer circumferential surface 13 c formed on the outer circumferential side and extending between the end faces 13 a and 13 b. The abrasive part 13 abrades an object with the outer circumferential surface 13 c. The dimensions of the abrasive part 13 are not particularly limited. The dimension in the width direction of the abrasive part 13 (dimension between end faces 13 a and 13 b) may be approximately from 3 to 1400 mm, and the diameter of the abrasive part 13 may be approximately from 50 to 1000 mm. Note that the direction in which the sheet member 14 is wound, which is the circumferential direction around the center axis line CL, is sometimes called the “winding direction.”

Examples of the non-woven fabric used in the abrasive part 13 include those formed from thermoplastic organic fibers such as polyamides (for example, nylon 6 and nylon 6,6 made from polycaprolactam or polyhexamethyladipamide), polyolefins (for example, polypropylene and polyethylene), polyesters (for example, polyethylene terephthalate), and polycarbonates. Non-woven fabric formed from nylon or polyester fiber is generally used.

The thickness of the fiber is generally approximately from 19 to 250 μm in diameter. The thickness of the non-woven fabric is generally approximately from 2 to 50 mm. The intersections and contact points of the arranged fibers are mutually bonded by frictional force, adhesive force, and the like. Adhesion between fibers may be achieved by fusing the fibers themselves or by using a separate adhesive.

The non-woven fabric contains abrasive particles. The abrasive particles include any known abrasive material, combinations of such materials, and aggregates. Examples of soft abrasive materials are not limited but include inorganic materials such as flint, silica, pumice, and calcium carbonate, organic polymer materials such as polyesters, polyvinyl chlorides, methacrylates, methyl methacrylates, polycarbonates, and polystyrenes, and any combinations of the above materials. Examples of hard abrasive materials are not limited but include aluminum oxides such as aluminum oxide, heat-treated aluminum oxide, and white aluminum oxide, and silicon carbide, alumina-zirconia, diamond, ceria, cubic boron nitride, and garnet, and combinations of the above materials.

An adhesive is used for bonding the fibers of the non-woven fabric with each other or bonding the abrasive particles with the fibers of the non-woven fabric. The adhesive used for bonding the fibers of the non-woven fabric with each other may be the same as or different from the adhesive used for bonding the abrasive particles with the fibers of the non-woven fabric. When the same adhesive is used, bonding of the fibers of the non-woven fabric with each other and bonding of the abrasive particles with the fibers of the non-woven fabric may be performed simultaneously during manufacturing.

Examples of the adhesive that bonds the non-woven fabric fibers to each other include, as examples of thermosetting adhesives, aqueous suspensions and organic solvent solutions of epoxy, melamine, phenol, isocyanate, and isocyanurate resin, or rubber-based polymer solutions or suspensions of SBR, SBS, SIS, and the like. These are applied to the fibers by dip coating, roll coating, spray coating, or the like, and then cured to make a non-woven fabric.

As illustrated in FIG. 2, a plurality of perforations 16 which penetrate in the thickness direction of the sheet member 14 are formed in the sheet member 14 which constitutes the abrasive part 13. The perforations 16 are formed by reeling the sheet member 14 using the apparatus illustrated in FIG. 4 and widening the slits 6. The perforations 16 that appear on the outer circumferential surface 13 c of the abrasive part 13 are formed in the outermost wound sheet member 14. Thus, the sheet member 14 wound on the inner circumferential side of the outermost sheet member 14 by an amount of one sheet is exposed from the perforations 16. Note that the outermost sheet member 14 is sometimes called “sheet member 14A,” and the sheet member 14 wound on the inner circumferential side of the sheet member 14A by an amount of one sheet is sometimes called “sheet member 14B.” Through such a configuration, a plurality of shallow grooves are formed on the outer circumferential surface 13 c of the abrasive part 13 by the edges of the perforations 16 of the sheet member 14A and the sheet member 14B exposed from the perforations 16.

The perforations 16 have a shape that extends in a first direction D1. Specifically, the perforations 16 have a shape such as an oval shape or a substantially rectangular shape including rhombus shapes, because they are originally created in a slit form and formed into the slits 6 by widening them. The perforations 16 have end parts 16 a and 16 a on the two end sides in the first direction D1. The end parts 16 a and 16 a correspond to the two ends of the slits 6 in the first direction D1 prior to widening. The perforations 16 are provided at a prescribed pitch in the first direction D1, and are provided at a prescribed pitch in a second direction D2 perpendicular to the first direction D1. In the present embodiment, the first direction D1 corresponds to the axial direction in which the center axis line CL extends. The second direction D2 corresponds to the winding direction, which is the direction in which the sheet member is wound.

The sheet member 14 which constitutes the abrasive part 13 is segmented into a plurality of regions 3 extending in the first direction D1 and arranged in the second direction. A boundary 4 is formed extending in the first direction D1 between a pair of regions 3. In FIG. 2, virtual lines corresponding to some of the boundaries 4 are shown. When viewed from the radial direction, the boundaries 4 form straight lines which extend straight in the first direction D1. Note that when the virtual lines of the boundaries 4 are shown on the entire circumference of the abrasive roll 1, the virtual lines of the boundary 4 are depicted as circles. A boundary 4 is defined as a reference line set for the perforations 16 that are aligned at a prescribed pitch in the first direction D1, among the plurality of perforations 16. The boundary 4 as a reference line is a line set so as to pass through the center position of each perforation 16 aligned in the first direction D1 and to pass through the end parts 16 a and 16 a. However, the positions of the end parts 16 a and 16 a may deviate and the virtual lines of the boundaries 4 do not have to completely overlap the end parts 16 a and 16 a due to manufacturing error.

As described above, when a virtual line is set so as to pass through substantially the center positions of a plurality of perforations 16 aligned in the first direction, the “boundary” corresponds to that virtual line. Furthermore, a “region” is a portion virtually delimited by a boundary 4 and a boundary 4. A region 3 serves as a band-like region spanning the entire circumference of the outer circumferential surface 13 c of the abrasive part 13. Note that in the band-like sheet member 14 in the unwound state, the boundary 4 is defined by a virtual line that passes through the linear slits 6, as illustrated in FIG. 4. The region 3 is set as a region in the direction of extension of the sheet member 14 where no slits 6 are formed.

As described above, the boundary 4 is set based on the perforations 16 aligned in the first direction D1. Thus, a plurality of perforations 16 are formed extending in the first direction at the boundaries 4. At the boundaries 4, a plurality of perforations 16 are disposed separated from each other in the first direction D1. The position at which the perforation 16 and perforation 16 are separated functions as a connecting part 7 which connects the regions 3 to each other. Thus, a pair of regions 3 adjoining in the second direction D2 are mutually connected by a connecting part 7 formed between perforations 16.

Specifically, a “connecting part” corresponds to a portion on the virtual line of the boundaries 4 where no perforations 16 are formed. The connecting part 7 is a portion affixed such that when a force is applied so as to widen each region 3 in the second direction, the opening thereof does not widen like the perforations 16 and adjoining regions 3 do not separate from each other.

In the present embodiment, the connecting part 7 of a boundary 4 formed on one side in the second direction D2 and the connecting part 7 of the boundary 4 formed on the other side, relative to a region 3, are disposed at different positions in the first direction D1. Note that “different positions” means that the center positions in the connecting parts 7 in the second direction D2 needs to differ each other, and can partially overlap as long as they differ from each other. The perforation 16 of a boundary 4 formed on one side in the second direction D2 and the perforation 16 of the boundary 4 formed on the other side, relative to a region 3, are disposed at different positions in the first direction D1. Specifically, for mutually adjoining boundaries 4, the perforation 16 of one of the boundaries and the perforation 16 of the other boundary 4 have a staggered positional relationship. Thus, a structure in which a plurality of perforations 16 (slits 6 before winding) are disposed in a staggered manner is sometimes called “skipping slits.” In the present embodiment, in adjoining boundaries 4 with one skip, the perforation 16 and the boundary 4 are disposed at the same position. Specifically, the pair of boundaries 4 are set to form a staggered pattern of perforations 16.

The dimensions of the region 3, perforation 16, and connecting part 7 configured as described above are not particularly limited but may be set as follows, for example. The dimension of the region 3 in the second direction D2 may be from 1 to 100 mm or from 5 to 50 mm. The dimension of the perforation 16 in the first direction D1 may be from 1 to 100 mm or from 5 to 50 mm. The dimension of the connecting part 7 in the first direction D1 may be from 1 to 100 mm or from 5 to 50 mm. Note that perforations 16 (that is, slits 6) may also be formed on only the sheet member 14 on the outer circumference among the wound sheet members 14.

Next, the method for manufacturing the abrasive roll 1 according to the present embodiment will be described with reference to FIGS. 4 to 7. In the manufacturing method, first, a step of preparing a non-woven fabric sheet member 14 in which a plurality of perforations 16 (slits 6) penetrate in the thickness direction is executed. In this step, a sheet member 14 in which a plurality of slits 6 arranged in a staggered manner are formed is prepared, as illustrated in FIG. 4. However, in FIG. 4, the width dimension of the sheet member 14 is set to the size of the completed abrasive roll 1 in the axial direction, but the sheet member at this stage is set to a width dimension (the width dimension equivalent to several abrasive rolls 1) that is larger than the dimension illustrated in FIG. 4. Note that at this stage of the process, the non-woven fabric sheet member 14 contains an adhesive for adhering abrasive particles thereto.

Next, a step of winding a sheet member 14 a plurality of times around the core member 12 extending in the axial direction is executed. However, the core member 12 at this stage has a length equivalent to several abrasive rolls 1. For example, dry winding is performed by the winding apparatus 50 illustrated in FIG. 4. The winding apparatus 50 includes a part that holds a roll body 51 of the sheet member 14 in which slits 6 have been formed. The winding apparatus 50 feeds the sheet member 14 from the roll body 51 and guides the sheet member 14 to a reeling part 52 via a plurality of rollers. The reeling part 52 winds the sheet member 14 around the core member 12 a plurality of times to form a roll body 54. Note that at this time, the sheet member 14 is wound in a state where tensile force so as to widen the slits 6 (refer to FIG. 4) is applied. Also note that the wound sheet member 14 may be affixed by a prescribed method so as to stay on the roll body 54.

Next, a step of adhering the wound sheet member 14 to the core member 12 is executed. This step includes a step of applying an adhesive to the sheet member 14 of the roll body 54 illustrated in FIG. 5 and a step of adhering the sheet member 14 by curing the adhesive. The method illustrated in FIG. 6 may be employed as the method of applying adhesive or the like to the sheet member 14 of the roll body 54. This method is executed by adhering an adhesive liquid to the roll body 54 by dipping the roll body 54 in the adhesive liquid in a dipping tank 61.

Next, a step of forming a plurality of adhesive rolls 1 is executed by cutting the roll body 54 at a plurality of locations in the axial direction. In this step, the roll body 54 is placed in a cutting apparatus. Then, the cutting apparatus cuts the sheet member 14 adhered to the roll body 54 and the core member 12 to a prescribed dimension. The adhered sheet member 14 is configured as an abrasive part 13. Note that the roll body 54 may be used unaltered as the abrasive roll 1 without executing the step of cutting the roll body 54. As a result, the abrasive roll 1 illustrated in FIG. 1 is obtained.

Next, the operation and effect of the abrasive roll 1 according to the present embodiment will be described.

The abrasive roll 1 includes a core member 12 extending in the axial direction and an abrasive part 13 including a sheet member 14 of non-woven fabric wound a plurality of times around the core member 12, wherein a plurality of perforations 16 penetrating in the thickness direction of the sheet member 14 are formed in the sheet member 14.

In the abrasive roll 1, a plurality of perforations 16 which penetrate in the thickness direction of the sheet member 14 are formed in the sheet member 14. In this case, the perforations 16 of the outermost sheet member 14A are formed on the outer circumferential surface 13 c of the abrasive part 13 which functions as an abrasive surface. As a result, a plurality of shallow grooves are formed on the outer circumferential surface 13 c of the abrasive part 13 by the edges of the perforations 16 of the sheet member 14A and the sheet member 14B exposed from the perforations 16. Thus, when the abrasive roll 1 abrades an object, abrasive force is increased by the action of the edge portions of the grooves of the outer circumferential surface 13 c (edges of the perforations 16). Furthermore, particles of the abraded object can flow into the grooves and escape, and therefore a reduction in abrasive force due to the abrasive surface being clogged with particles is prevented. Additionally, abrasiveness can be improved by a simple configuration in which perforations 16 are simply formed in a sheet member 14. As a result, abrasiveness can be easily improved.

In the abrasive roll 1, the sheet member 14 may be segmented into a plurality of regions 3 extending in the first direction D1 and arranged in the second direction D2, and a boundary 4 extending in the first direction D1 may be formed between a pair of the regions 3. At the boundary 4, perforations 16 extending in the first direction D1 may be formed, and a pair of the regions 3 adjoining in the second direction D2 may be mutually connected by a connecting part 7 formed on an end side of the perforation 16 in the first direction D1. As a result, the perforations 16 can be arranged in the first direction D1 and the second direction D2 on the outer circumferential surface 13 c of the abrasive part 13. Thus, abrasiveness can be improved as described above across a wide range of the outer circumferential surface 13 c. Furthermore, the connecting part 7 mutually connects the regions 3, and therefore damage such as tearing of the outermost sheet member 14A of the abrasive part 13 can be reduced even when the perforations 16 described above are formed.

In the abrasive roll 1, a plurality of the perforations 16 may be formed at the boundary 4, the perforations 16 being disposed separated from each other in the first direction D1. A pair of the regions 3 adjoining in the second direction D2 may be mutually connected by the connecting part 7 formed between the perforations 16. The connecting part 7 of the boundary 4 formed on one side in the second direction D2 and the connecting part 7 of the boundary 4 formed on the other side, relative to the region 3, may be disposed in different positions in the first direction D1. For example, at locations where the perforations 16 are formed closely in the second direction D2, the abrasiveness improvement effect described above is easily obtained, while on the other hand, the strength of the sheet member 14 tends to decrease. On the other hand, in locations where the connecting parts 7 are formed closely in the second direction D2, the strength of the sheet member 14 can be easily assured, but on the other hand, the abrasiveness improvement effect is not readily obtained. Thus, disposing the connecting parts 7 in a staggered manner can provide a good balance between the effect of improving abrasiveness and the effect of assuring strength of the sheet member 14 across a wide range of the outer circumferential surface 13 c of the abrasive part 13.

In the abrasive roll 1, the first direction D1 may be the winding direction of the sheet member 14 and the second direction D2 may be the axial direction. In this case, when the sheet member 14 is wound around the core member 12, winding is performed in a state where tension of a prescribed magnitude is applied to the sheet member 14 in the axial direction in order to widen the slits 6 in the sheet member 14 to an appropriate size to form perforations 16. On the other hand, the perforations 16 do not widen excessively even when tension is applied to the sheet member 14 in the winding direction when the sheet member 14 is wound around the core member 12. Thus, the sheet member 14 can be wound around the core member 12 while sufficiently assuring tension on the sheet member 14 in the winding direction.

The method for manufacturing the abrasive roll 1 according to the present embodiment includes preparing a non-woven fabric sheet member 14 in which a plurality of perforations 16 penetrating in the thickness direction are formed, winding the sheet member 14 a plurality of times around a core member 12 extending in the axial direction, and adhering the wound sheet member 14 to the core member 12.

According to this method for manufacturing the abrasive roll 1, the same operation and effect as the abrasive roll 1 described above can be obtained.

The present invention is not limited to the embodiments described above and may be modified as appropriate.

The arrangement structure of the perforations 16 is not limited to the embodiments described above. For example, the structure illustrated in FIG. 7 may also be employed. In FIG. 7, the first direction D1 is the axial direction and the second direction D2 is the winding direction of the sheet member 14. As a result, the perforations 16 extend in the axial direction and are arranged in the winding direction. In this case, when viewed along the winding direction of the sheet member 14, perforations 16 are present in the entire area in the axial direction of the outer circumferential surface 13 c of the abrasive part 13. Thus, for the processing surface of the object, the perforations 16 can be assured across the entire width of the abrasive roll 1. Furthermore, it is possible to not provide a plurality of perforations 16 in the axial direction as illustrated in FIG. 7, and to form one large perforation 16 in the axial direction as illustrated in FIG. 8.

Furthermore, the connecting part 7 of the boundary 4 formed on one side in the second direction D2 and the connecting part 7 of the boundary 4 formed on the other side, relative to the region 3, may be disposed at the same position in the first direction D1. Thus, the perforations 16 do not necessarily have to be disposed in a staggered manner. Additionally, in the embodiments illustrated in FIGS. 2 and 7, two boundaries 4 are set to form a staggered pattern of perforations 16. Instead, a greater number of boundaries 4 may also be set to form a staggered pattern of perforations 16. Alternatively, the arrangement pattern of the perforations 16 does not have to be particularly regular.

Furthermore, in the embodiments described above, the perforations 16 are formed extending in the first direction D1 only. Perforations 16 may be additionally formed extending in the second direction D2.

REFERENCE NUMERALS

-   1 Abrasive roll, -   3 Region, -   4 Boundary, -   7 Connecting part, -   12 Core member, -   13 Abrasive part, -   14 Sheet member, -   16 Perforation 

1. An abrasive roll comprising: a core member extending in an axial direction; and an abrasive part including a sheet member of non-woven fabric wound a plurality of times around the core member, wherein a plurality of perforations penetrating in a thickness direction of the sheet member are formed in the sheet member.
 2. The abrasive roll according to claim 1, wherein the sheet member is segmented into a plurality of regions extending in a first direction and arranged in a second direction; a boundary extending in the first direction is formed between a pair of the regions; a perforation extending in the first direction is formed at the boundary; and a pair of the regions adjoining in the second direction are mutually connected by a connecting part formed on an end side of the perforation in the first direction.
 3. The abrasive roll according to claim 2, wherein a plurality of the perforations are formed at the boundary, the perforations being disposed separated from each other in the first direction; a pair of the regions adjoining in the second direction are mutually connected by the connecting part formed between the perforations; and the connecting part of the boundary formed on one side in the second direction and the connecting part of the boundary formed on the other side, relative to the region, are disposed in different positions in the first direction.
 4. The abrasive roll according to claim 2, wherein the first direction is the axial direction and the second direction is a winding direction of the sheet member.
 5. The abrasive roll according to claim 2, wherein the first direction is a winding direction of the sheet member and the second direction is the axial direction.
 6. A method for manufacturing an abrasive roll, the method comprising preparing a non-woven fabric sheet member in which a plurality of perforations penetrating in a thickness direction are formed; winding the sheet member a plurality of times around a core member extending in an axial direction; and adhering the wound sheet member to the core member. 